Previously I had started the carb heat door fitting with a thin piece of aluminum cut from a cardboard template. Today I drilled the template door to the hinge and fine tuned. I then got some thicker aluminum (032) and traced out and match drilled and then sanded to the template.
I positiojned and marked and drilled the steel angle arm to fit so that it wil allow the door to swing down and up without catching on anything and then drilled. I also trimmed and rounded the excess material away.
When I had door and hinges all drilled and fitted, I had Brenda deburr them for me and sand and polish it all up.
I clecoed it all together and checked final fit ok, Bent the door flap slightly so that it seals nice when open.
Countersunk rivit holes in the hinge and then rivited the hinge and spacer to the door flap. Riveted the last two holes including the angle arm lever. Used bigger rivits here only because I had miss drilled the holes to #40 instaead of #30..
Cut a spacer for the adel clamp that will hold the bowden cable aft of the swing arm and installed per plans. The cable will be inserted on final install.
Still have the carb heat scat tube flange to rivit on and some baffle material to reach the snorkle. Its been a time conuming little poject I must say.
A bead of tank sealant or high temp RTV can be used to the flap door edge to help seal and keep the pieces from vibrating on eachother while in open position. I will do this later. Also the inside of BAB box can use some sanding to remove the sctaches made while sanding fiberglas layups made earlier. At that point I can rivit on the FAB box and either paint the exterior or just leave raw for now...Undecided. At least it will be ready for install on carb
Hinges drilled to door flap
New ticker door fabricated and rivited with cable lever to the top plate
Viewing carb heat door installed and in the down (carb heat on) position
